System and method for real-time material carryback deduction in loading and dumping work cycles

ABSTRACT

A system and method are provided for real-time deduction of material carryback in a loading container of a transport vehicle, wherein the material is loaded in the loading container by a work machine at a first site and dumped from the loading container by the transport vehicle at a second site. A first sensor (e.g., a camera associated with the work machine) provides first data corresponding to a volume of material loaded in the loading container in a first work state (e.g., loaded). A second sensor (e.g., a camera or a payload measuring unit associated with the transport vehicle) provides second data corresponding to a volume of material loaded in the loading container in a second work state (e.g., unloaded). A generated output signal corresponds to a calculated total volume of material associated with a work cycle, said total volume based on at least the provided first and second data.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to work cycles including workmachines for material loading and transport vehicles for carrying anddumping the loaded material, and more particularly to systems andmethods for real-time carryback deduction with respect to the loadedmaterial.

BACKGROUND

Work machines as discussed herein may particularly refer to excavatormachines for illustrative purposes, but may also for example includevarious other machines and equipment, self-propelled or otherwise, whichmodify the terrain or equivalent working environment in some way, andfurther are responsible for loading material from the proximate terraininto transport vehicles for delivery to a separate dumping site. Trackedor wheeled ground engaging units support an undercarriage from theground surface, and the undercarriage may typically further support oneor more work attachments (also or otherwise referred to as workimplements) which are used to dig or otherwise extract material from theterrain and to selectively discharge the material into a loading areaassociated with the transport vehicles, such as for example thecontainer of an articulated dump truck.

As used herein, the term “carryback material” may refer to materialwhich undesirably remains in the loading container of the transportvehicle after the dumping process. This may occur for any number ofreasons including for example wet conditions, an inherent property ofthe material being transported, a configuration of the loadingcontainer, a grade of the dumping site, or the like. The presence ofmaterial carryback is undesirable at least because of the addedinefficiencies in the work cycle, but also because it adds uncertaintyin the estimation of the volume of material loaded and transportedduring the work cycle. While payload weight can be more preciselymeasured for each load, volume is more important to the end users, andconventional methods for estimating volume from measured payload weightare relatively imprecise. Accordingly, it may typically be necessary towait until all of the material has been spread at a destination site,and then conduct measurements with a drone.

It would therefore be desirable to provide an easy and effective way tomeasure and accordingly deduct the amount of carryback material in agiven load. Unfortunately, cameras or equivalent imaging devices on atransport vehicle such as an articulated dump truck are unable to scanor otherwise measure the contents of a loading container when it isfilled with material. In addition, cameras or equivalent imaging devicesmounted on the work machine such as an excavator in many applicationswill be unable to scan or otherwise measure material on the bottom ofthe loading container.

BRIEF SUMMARY

The current disclosure provides an enhancement to conventional systems,at least in part by introducing a novel system and method for utilizingmultiple image data sources mounted on multiple machines or vehicles inthe work cycle and coordinated data processing for carryback deduction.

In one embodiment, a method as disclosed herein is provided forreal-time deduction of material carryback in a loading container of atransport vehicle, wherein the material is loaded in the loadingcontainer by a work machine at a first site and dumped from the loadingcontainer by the transport vehicle at a second site. A first sensor isassociated with one of the work machine or the transport vehicle andprovides first data corresponding to a volume of material loaded in theloading container in a first work state. A second sensor is associatedwith the other of the work machine or the transport vehicle, andprovides second data corresponding to a volume of material loaded in theloading container in a second work state. An output signal may befurther generated corresponding to a calculated total volume of materialassociated with a work cycle, with the total volume being calculatedbased at least in part on the provided first data and the providedsecond data.

In one exemplary aspect according to the above-referenced embodiment,the generated output signal is provided to populate a data structurewith the calculated total volume of material in association with atleast one of the first site and the second site.

In another exemplary aspect according to the above-referencedembodiment, a first volume may be determined based at least in part onthe provided first data and information regarding one or more dimensionsof the loading container, a second volume may be determined based atleast in part on the provided second data and the information regardingone or more dimensions of the loading container, and the total volume ofmaterial associated with the work cycle is calculated based on adifference between the determined first and second volumes.

In another exemplary aspect according to the above-referencedembodiment, the information regarding one or more dimensions of theloading container may be stored in association with the transportvehicle, wherein the first sensor is associated with the work machine,the first data is transmitted from the work machine to the transportvehicle, and the first volume is calculated based on the transmittedfirst data and the stored information regarding one or more dimensionsof the loading container.

In another exemplary aspect according to the above-referencedembodiment, the first sensor may comprise a first image data sourceconfigured to generate signals corresponding to a first profile ofmaterial loaded in the loading container in the first work state, thesecond sensor may comprise a second image data source configured togenerate signals corresponding to a second profile of material loaded inthe loading container in the second work state, and the total volume iscalculated based at least in part on a determined first profile and adetermined second profile of loaded material.

In another exemplary aspect according to the above-referencedembodiment, the information regarding one or more dimensions of theloading container is obtained via scanned images from the first imagedata source and/or the second image data source.

In another exemplary aspect according to the above-referencedembodiment, the information regarding one or more dimensions of theloading container is retrieved from data storage based upon scannedimages comprising an identifier associated with the transport vehicle.

In another exemplary aspect according to the above-referencedembodiment, the information regarding one or more dimensions of theloading container is retrieved from data storage based uponcommunications between the work machine and the transport vehicle andcomprising an identifier associated with the transport vehicle.

In another exemplary aspect according to the above-referencedembodiment, the first sensor may comprise an image data sourceassociated with the work machine and configured to generate signalscorresponding to a profile of material loaded in the loading containerin the first work state, and the second sensor may comprise a payloadmeasuring unit associated with the transport vehicle.

In another exemplary aspect according to the above-referencedembodiment, a material density of material loaded in the transportvehicle may be determined based on input from the first sensor in thefirst work state and on input from the payload measuring unit in thefirst work state. A volume of material remaining in the transportvehicle in the second work state may be determined based on input fromthe payload measuring unit in the second work state and further in viewof the determined material density. The information regarding one ormore dimensions of the loading container may be obtained via scannedimages from the image data source. The information regarding one or moredimensions of the loading container may be retrieved from data storagebased upon scanned images comprising an identifier associated with thetransport vehicle, and/or based upon communications between the workmachine and the transport vehicle and comprising an identifierassociated with the transport vehicle.

In another embodiment, a system is disclosed herein for real-timededuction of material carryback in a loading container of a transportvehicle, wherein the material is loaded in the loading container by awork machine at a first site and dumped from the loading container bythe transport vehicle at a second site. The system includes a firstsensor associated with one of the work machine or the transport vehicleand configured to provide first data corresponding to a volume ofmaterial loaded in the loading container in a first work state, and asecond sensor associated with the other of the work machine or thetransport vehicle and configured to provide second data corresponding toa volume of material loaded in the loading container in a second workstate. A computing device includes a computer-readable medium residingon one of the work machine or the transport vehicle and having programinstructions residing thereon, said program instructions executable by aprocessor to direct the performance of steps in a method according tothe above-referenced embodiment and optionally any of the exemplaryaspects associated therewith.

Numerous objects, features and advantages of the embodiments set forthherein will be readily apparent to those skilled in the art upon readingof the following disclosure when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view representing an exemplary work machineaccording to the present disclosure.

FIG. 2 is a perspective view representing an exemplary transport vehicleaccording to the present disclosure.

FIG. 3 is a perspective view representing an image data source locatedon the work machine of FIG. 1, scanning a profile of material loaded onthe transport vehicle of FIG. 2 in a first work state.

FIG. 4 is a perspective view representing an image data source locatedon the transport vehicle of FIG. 2, scanning a profile of materialremaining in the loading container in a second work state.

FIG. 5 is a block diagram representing a control system for the workmachine according to an embodiment of the present disclosure.

FIG. 6 is a block diagram representing a control system for thetransport vehicle according to an embodiment of the present disclosure.

FIG. 7 is a flowchart representing an exemplary method according to anembodiment of the present disclosure.

DETAILED DESCRIPTION

Referring now to FIGS. 1-7, various embodiments may now be described ofan inventive system and method.

FIG. 1 in a particular embodiment as disclosed herein shows arepresentative work machine 20 in the form of, for example, a trackedexcavator machine. The work machine 20 includes an undercarriage 22 withfirst and second ground engaging units 24 driven by first and secondtravel motors (not shown), respectively.

A main frame 32 is supported from the undercarriage 22 by a swingbearing 34 such that the main frame 32 is pivotable about a pivot axis36 relative to the undercarriage 22. The pivot axis 36 is substantiallyvertical when a ground surface 38 engaged by the ground engaging units24 is substantially horizontal. A swing motor (not shown) is configuredto pivot the main frame 32 on the swing bearing 34 about the pivot axis36 relative to the undercarriage 22.

A work implement 42 in the context of the referenced work machine 20includes a boom assembly with a boom 44, an arm 46 pivotally connectedto the boom 44, and a working tool 48. The term “implement” may be usedherein to describe the boom assembly (or equivalent thereof)collectively, or individual elements of the boom assembly or equivalentthereof. The boom 44 is pivotally attached to the main frame 32 to pivotabout a generally horizontal axis relative to the main frame 32. Theworking tool in this embodiment is an excavator shovel (or bucket) 48which is pivotally connected to the arm 46. The boom assembly extendsfrom the main frame 32 along a working direction of the boom assembly.The working direction can also be described as a working direction ofthe boom 44. As described herein, control of the work implement 42 mayrelate to control of any one or more of the associated components (e.g.,boom 44, arm 46, tool 48).

It is within the scope of the present disclosure that the work machine20 may take various alternative forms and further utilize alternativework implements 42 to modify the proximate terrain.

In the embodiment of FIG. 1, the first and second ground engaging units24 are tracked ground engaging units, although various alternativeembodiments of a work machine 20 are contemplated wherein the groundengaging units 24 may be wheeled ground engaging units. Each of thetracked ground engaging units 24 includes an idler 52, a drive sprocket54, and a track chain 56 extending around the idler 52 and the drivesprocket 54. The travel motor of each tracked ground engaging unit 24drives its respective drive sprocket 54. Each tracked ground engagingunit 24 is represented as having a forward traveling direction 58defined from the drive sprocket 54 toward the idler 52. The forwardtraveling direction 58 of the tracked ground engaging units 24 alsodefines a forward traveling direction 58 of the undercarriage 22 andthus of the work machine 20. In some applications, including uphilltravel as further discussed below, the orientation of the undercarriage22 may be reversed such that a traveling direction of the work machine20 is defined from the idler 52 toward its respective drive sprocket 54,whereas the work implement(s) 42 is still positioned ahead of theundercarriage 22 in the traveling direction.

Although an excavator as the work machine 20 may be self-propelled inaccordance with the above-referenced elements, other forms of workmachines 20 may be contemplated within the scope of the presentdisclosure that are not self-propelled, unless otherwise specificallynoted.

An operator's cab 60 may be located on the main frame 32. The operator'scab 60 and the work implement 42 (e.g., boom assembly) may both bemounted on the main frame 32 so that the operator's cab 60 faces in theworking direction 58 of the boom assembly. A control station (not shown)may be located in the operator's cab 60. The control station may includeor otherwise be associated with a user interface as further describedbelow. As used herein, directions with regard to work machine 20 may bereferred to from the perspective of an operator seated within theoperator cab 60; the left of the work machine is to the left of such anoperator, the right of the work machine is to the right of such anoperator, a front-end portion (or fore) of the work machine is thedirection such an operator faces, a rear-end portion (or aft) of thework machine is behind such an operator, a top of the work machine isabove such an operator, and a bottom of the work machine below such anoperator.

Also mounted on the main frame 32 is an engine 64 for powering the workmachine 20. The engine 64 may be a diesel internal combustion engine,but is not so limited and within the scope of the present disclosure thework machine 20 may alternatively be driven by a non-combustion powersource (not shown). The engine 64 may drive a hydraulic pump to providehydraulic power to the various operating systems of the work machine 20.

An articulated dump truck as representing a transport vehicle 10 in FIG.2 may include a plurality of wheels and associated axles, and a frame 12supporting a loading container 14 (e.g., truck bed) having for example aloading surface at the bottom of an interior area surrounded bysidewalls, and a top edge at least part of which may typically be inparallel with the ground surface. A hydraulic piston-cylinder unit 16may be coupled between the frame 12 and the loading container 14 andconfigured to selectively extend and raise/pivot the loading container14 rearward to a dumping position, and to retract and lower/pivot theloading container forward from the dumping position to a travel andloading position (as shown). An operator's cab 18 of the transportvehicle 10 may be located on the frame 12, wherein directions withregard to the transport vehicle 10 may be referred to from theperspective of an operator seated within the operator cab 18; the leftof the transport vehicle is to the left of such an operator, the rightof the transport vehicle is to the right of such an operator, afront-end portion (or fore) of the transport vehicle is the directionsuch an operator faces, a rear-end portion (or aft) of the transportvehicle is behind such an operator, a top of the transport vehicle isabove such an operator, and a bottom of the transport vehicle below suchan operator.

A controller 212 for the transport vehicle 10 may in some embodimentscomprise or otherwise be associated with an operator interface in theoperator's cab 18, as further described below.

Referring next to FIG. 3, an image data source 104 (not shown in FIG. 1)may be mounted on the work machine 20 in accordance with the presentdisclosure. The location of the image data source 104 may be chosen suchthat a field of view 106 encompasses the loading container 14 of thetransport vehicle 10 during at least a portion of a material loadingoperation as a first work state wherein the surface of the loadingcontainer is retracted into a substantially horizontal orientation asshown, and may preferably be chosen such that the field of view 106encompasses all four top edges of the loading container 14. Asrepresented in FIG. 3, the work machine 20 is on the same level relativeto the transport vehicle 10, but it may be appreciated that in variousloading applications the work machine 20 may be in an elevated positionrelative to the transport vehicle 10 and/or at various respectiveorientations relative to each other. In some embodiments, a plurality ofimage data sources 104 or an image data source 104 that is moveable orreconfigurable in position may be provided to account for thedifferences in potential relative elevations, positions, andorientations with respect to a transport vehicle during loading.

Referring to FIG. 4, another image data source 204 (not shown in FIG. 2)may be mounted on the transport vehicle 10 in accordance with thepresent disclosure. The location of the image data source 204 may bechosen such that a field of view 206 encompasses the loading container14 of the transport vehicle 10 upon at least completion of a materialdumping operation as a second work state wherein the surface of theloading container is pivoted into an angled orientation as shown, andmay preferably be chosen such that the field of view 206 fullyencompasses a bottom surface of the loading container 14.

As schematically illustrated in FIG. 5, the work machine 20 includes acontrol system including a controller 112. The controller 112 may bepart of the machine control system of the work machine 20, or it may bea separate control module.

As referenced above, the controller 112 is configured to receive inputsignals from some or all of various image data sources 104 such ascameras and collectively defining an imaging system. The image datasources 104 may include video cameras configured to record an originalimage stream and transmit corresponding data to the controller 112. Inthe alternative or in addition, the image data sources 104 may includeone or more of an infrared camera, a stereoscopic camera, a PMD camera,or the like. One of skill in the art may appreciate that high resolutionlight detection and ranging (LiDAR) scanners, radar detectors, laserscanners, and the like may be implemented as image data sources withinthe scope of the present disclosure. The number and orientation of saidimage data sources 104 may vary in accordance with the type of workmachine 20 and relevant applications, but may at least be provided withrespect to an area in a travelling direction of the work machine 20 andconfigured to capture image data associated with a loading areaproximate the work machine 20 such as for example corresponding toloading container 14.

The position and size of an image region recorded by a respective cameraas an image data source 104 may depend on the arrangement andorientation of the camera and the camera lens system, in particular thefocal length of the lens of the camera, but may desirably be configuredto capture substantially the entire loading container 14 throughout aloading operation. One of skill in the art may further appreciate thatimage data processing functions may be performed discretely at a givenimage data source if properly configured, but also or otherwise maygenerally include at least some image data processing by the controlleror other downstream data processor. For example, image data from any oneor more image data sources may be provided for three-dimensional pointcloud generation, image segmentation, object delineation andclassification, and the like, using image data processing tools as areknown in the art in combination with the objectives disclosed.

The controller 112 of the work machine 20 may be configured to produceoutputs, as further described below, to a user interface 114 associatedwith a display unit 118 for display to the human operator. Thecontroller 112 may be configured to receive inputs from the userinterface 114, such as user input provided via the user interface 114.Not specifically represented in FIG. 5, the controller 112 of the workmachine 20 may in some embodiments further receive inputs from andgenerate outputs to remote devices associated with a user via arespective user interface, for example a display unit with touchscreeninterface. Data transmission between for example the vehicle controlsystem and a remote user interface may take the form of a wirelesscommunications system and associated components as are conventionallyknown in the art. In certain embodiments, a remote user interface andvehicle control systems for respective work machines 20 may be furthercoordinated or otherwise interact with a remote server or othercomputing device for the performance of operations in a system asdisclosed herein.

The controller 112 may in various embodiments be configured to generatecontrol signals for controlling the operation of respective actuators,or signals for indirect control via intermediate control units,associated with a machine steering control system 126, a machineimplement control system 128, and an engine speed control system 130.The control systems 126, 128, 130 may be independent or otherwiseintegrated together or as part of a machine control unit in variousmanners as known in the art. The controller 112 may for example generatecontrol signals for controlling the operation of various actuators, suchas hydraulic motors or hydraulic piston-cylinder units (not shown), andelectronic control signals from the controller 112 may actually bereceived by electro-hydraulic control valves associated with theactuators such that the electro-hydraulic control valves will controlthe flow of hydraulic fluid to and from the respective hydraulicactuators to control the actuation thereof in response to the controlsignal from the controller 112.

A reading device 132 as conventionally known in the art such as forexample an RFID device, barcode scanner, or the like may further beprovided and communicatively linked to the controller 112 for obtainingreadable information associated with a particular transport vehicle 10.

A pose sensor unit 134 may further be linked to the controller 112 forcapturing and processing data associated with for example a current orpredicted pose of the loading container 14 of a transport vehicle 10.The pose sensor unit 134 in certain embodiments may be integrated orotherwise associated with the image data source(s) 104, for examplewhere images of the loading container are captured and processed toassociate a current pose with a respective work state. The pose sensorunit 134 in certain embodiments may be integrated or otherwiseassociated with a reading device 132, for example where data is capturedor otherwise received from the transport vehicle in association with acurrent loading container pose and further with a respective work state.

The controller 112 includes or may be associated with a processor 150, acomputer readable medium 152, a communication unit 154, and data storage156 such as for example a database network. It is understood that thecontroller 112 described herein may be a single controller having someor all of the described functionality, or it may include multiplecontrollers wherein some or all of the described functionality isdistributed among the multiple controllers.

Various operations, steps or algorithms as described in connection withthe controller 112 can be embodied directly in hardware, in a computerprogram product such as a software module executed by the processor 150,or in a combination of the two. The computer program product can residein RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory,registers, hard disk, a removable disk, or any other form ofcomputer-readable medium 152 known in the art. An exemplarycomputer-readable medium 152 can be coupled to the processor 150 suchthat the processor 150 can read information from, and write informationto, the memory/storage medium 152. In the alternative, the medium 152can be integral to the processor 150. The processor 150 and the medium152 can reside in an application specific integrated circuit (ASIC). TheASIC can reside in a user terminal. In the alternative, the processor150 and the medium 152 can reside as discrete components in a userterminal.

The term “processor” 150 as used herein may refer to at leastgeneral-purpose or specific-purpose processing devices and/or logic asmay be understood by one of skill in the art, including but not limitedto a microprocessor, a microcontroller, a state machine, and the like. Aprocessor 150 can also be implemented as a combination of computingdevices, e.g., a combination of a DSP and a microprocessor, a pluralityof microprocessors, one or more microprocessors in conjunction with aDSP core, or any other such configuration.

The communication unit 154 may support or provide communications betweenthe controller 112 and external communications units, systems, ordevices, and/or support or provide communication interface with respectto internal components of the work machine 20. The communications unitmay include wireless communication system components (e.g., via cellularmodem, WiFi, Bluetooth or the like) and/or may include one or more wiredcommunications terminals such as universal serial bus ports.

The data storage 156 as further described below may, unless otherwisestated, generally encompass hardware such as volatile or non-volatilestorage devices, drives, electronic memory, and optical or other storagemedia, as well as in certain embodiments one or more databases residingthereon.

As schematically illustrated in FIG. 6, in embodiments of a system asdisclosed herein the plurality of transport vehicles 10 may each includea respective control system including a controller 212. The controller212 may be part of a vehicle control system of the transport vehicle 10,or it may be a separate control module.

The controller 212 of a respective transport vehicle 10 may beconfigured to receive input signals from a payload measuring unit 222 asis conventionally known in the art for certain articulated dump trucks.The controller 212 may further integrate or otherwise communicate with adumping control system 224 to selectively direct the operation of thehydraulic piston-cylinder unit 16 for articulating the loading container14 between a loading position and a dumping position. The transportvehicle 10 may further comprise a barcode 332 or otherwise generateanother form of machine-readable identifier 232 such as for example anRFID signal via a transceiver for communicating readable information toa work machine 20 or the like.

A pose sensor unit 234 may further be linked to the controller 212 forcapturing and processing data associated with for example a current orpredicted pose of the loading container 14 of the transport vehicle 10.The pose sensor unit 234 in certain embodiments may be integrated orotherwise associated with the image data source(s) 204, for examplewhere images of the loading container are captured and processed toassociate a current pose with a respective work state. The pose sensorunit 234 in certain embodiments may be integrated or otherwiseassociated with a machine control system or with a user interface 214,for example to receive inputs corresponding to a commanded position ofthe loading container or output signals for controlling the pose of theloading container via the dumping control system 224.

In certain embodiments, the controller 212 may further integrate orotherwise communicate with image data sources 204 such asvehicle-mounted cameras or the like, as described above.

The controller 212 of a respective transport vehicle 10 may beconfigured to produce outputs, as further described below, to the userinterface 214 associated with a display unit 218 for display to thehuman operator. The controller 212 may be configured to receive inputsfrom the user interface 214, such as user input provided via the userinterface 214.

The controller 212 of a respective transport vehicle 10 may furtherinclude or be associated with a processor 250, a computer readablemedium 252, a communication unit 254, and data storage 256 such as forexample a database network. It is understood that the controller 212described herein may be a single controller having some or all of thedescribed functionality, or it may include multiple controllers whereinsome or all of the described functionality is distributed among themultiple controllers.

Referring next to FIG. 7, with further illustrative reference back toFIGS. 1-6, an embodiment of a method 300 may now be described which isexemplary but not limiting on the scope the present disclosure unlessotherwise specifically noted. One of skill in the art may appreciatethat alternative embodiments may include fewer or additional steps, andthat certain disclosed steps may for example be performed in differentchronological order or simultaneously. Unless otherwise specificallynoted, operations, steps, functions, processes, and the like asdisclosed in association with the method 300 may be executed or directedby a single computing device, or via multiple computing devices inoperable communication via a communications network. Exemplary suchcomputing devices may include onboard controllers or machine controlsystems, remote servers, mobile user devices, and the like.

A first step 310 may include detecting a first pose of the loadingarea/loading container 14 for a transport vehicle 10, for example inassociation with a first work state such as a loading stage. In thecontext of an excavator as the work machine 20 loading material into aloading container of an articulated dump truck as the transport vehicle10, the first work state may be associated with a loading container posewherein the loading container is fully retracted for receiving materialand optionally further wherein the transport vehicle is appropriatelypositioned with respect to the frame 12 of the work machine 20. An imagedata source 104 may be mounted on the work machine, for example on anunderside of the work implement 42 but not expressly limited thereto,such that images may be sufficiently captured for processing the upperedges of the loading container and determining for example theorientation of the loading container with respect to the ground surface.

When the loading process is determined to be complete (i.e., “yes” inresponse to query of step 320), for example via a manual user input orother form of input signal or processed image data, the method maycontinue in step 330 by scanning a profile of the loaded material in theloading container via the image data source(s) 104 mounted on the workmachine 20. As previously noted, an image data source 204 mounted on thetransport vehicle 10 will typically be unable to capture the profile ofmaterial because the material is loaded high enough relative to thecontours of the loading container to block the respective field of view206.

As previously noted, the profile may be scanned and further analyzedusing for example three-dimensional point cloud generation, imagesegmentation, object delineation and classification, and the like, usingimage data processing tools as are known in the art, further optionallyin view of a reference profile corresponding to predetermined contoursof the loading container 14, so as to for example estimate a volume ofthe material loaded in the container based on the scanned profile.Certain dimensions such as information generally corresponding torelevant contours of the loading container 14 may be determineddynamically using the image data source, or a reference profile may bepredetermined and retrieved from data storage upon identifying theparticular transport vehicle 10 or type of transport vehicle, or may beinput directly from the user interface, etc. For example, informationregarding one or more dimensions of the loading container 14 may bestored in association with the transport vehicle 10, wherein thedetected first profile is associated with the work machine 20 and istransmitted from the work machine to the transport vehicle 10, and thefirst volume is calculated based on the transmitted detected firstprofile and the stored information regarding one or more dimensions ofthe loading container 14.

In an embodiment, raw data corresponding to the scanned profile may becaptured by the image data source 104 on the work machine 20 and thentransmitted to the transport vehicle 10, which has no need to obtainreference profile data corresponding to dimensions such as for examplerelating to the contours of the loading container 14 from anotherlocation and accordingly can make volume estimations without such asub-step. In certain embodiments, a model may be implemented whichestimates the volume of material directly from the scanned profilewithout supplemental reference to the contours of the loading container14 or other parameters. Such a model may be developed and implemented inthe form of a look-up table based on defined levels of the materialrelative to one or more identified contours/edges of the loadingcontainer 14, or may be incrementally refined over time using machinelearning techniques, or the like.

A next step 340 may include detecting a second pose of the loadingarea/loading container 14 for the transport vehicle 10, for example inassociation with a second work state such as a dumping stage. In theabove-referenced context of an articulated dump truck as the transportvehicle 10, the second work state may be associated with a loadingcontainer pose wherein the piston-cylinder unit 16 coupled to theloading container 14 is substantially fully extended for dumpingmaterial out of the loading container 14. In an embodiment, a signal maybe generated to indicate that the loading container 14 is pivoted to thesecond pose, such as for example from a sensor associated with thepiston-cylinder unit 16 or a manual input from a user interface. Thesecond pose may be determined from the processing of images from theimage data source 204.

When the dumping process is determined to be complete (i.e., “yes” inresponse to query of step 350), for example via a manual user input orother form of input signal or processed image data, the method maycontinue in step 360 by scanning a profile of any remaining material inthe loading container 14 after dumping. The scanned profile may begenerated via the image data source 204 which may for example be mountedabove a plane corresponding to an upper edge of the loading container14, and configured such that images may be sufficiently captured forprocessing at least a bottom surface of the loading container 14. Aspreviously noted, an image data source 104 mounted on the work machine20 may be unable to reliably capture the profile of material remainingin the otherwise empty loading container 14 because the respective fieldof view 106 typically does not extend to the bottom surface of theloading container 14.

The profile of remaining (carryback) material in the second work statemay for example be scanned and further analyzed in similar fashion aswith the profile of loaded material in the first work state, but theprocessing techniques are not necessarily the same and may be performedin different locations in certain embodiments.

The next step 370 as represented in FIG. 7 may include transmission ofthe scanned profiles and/or processed volume data from an initiallocation to a downstream location for additional processing and tosupport further functions such as reporting, displaying, control, or thelike.

For example, and as initially referenced above, in an embodiment rawdata from an initial scan of loaded material in the loading container 14as captured by an image data source mounted on the work machine 20 maybe transmitted to the transport vehicle 10. The scan data may beprovided in an input data string along with an identifier for the workmachine, an identifier for the loading site, and/or the like, such thatsuch first scan data may be supplemented with additional scan data afterthe loading container 14 has been substantially emptied and computationsperformed against the respective scans to determine a total volumedumped in the current iteration of a work cycle. Generally stated, ifthe second scan yields no carryback material in the loading container14, then all of the material loaded in the loading container 14 at thetime of the first scan, or in other words everything that has beendumped on the ground prior to the time of the second scan, may betreated as positive yardage. Alternatively, if the second scan yields aprofile corresponding to a certain amount of carryback material in theloading material 14, a volume of material dumped on the ground prior tothe time of the second scan may be calculated/estimated based on acomparison of the respective scans further optionally in view ofsupporting parameters such as the contours of the loading container 14.

In an embodiment, a material density may be determined based at least ona first input (e.g., from the payload measuring unit) taken beforematerial is loaded in the transport vehicle 10, a second input (e.g.,from an image data source 104 on the work machine 20) after the materialis loaded in the transport vehicle 10, and further on a third input(e.g., from the payload measuring unit) taken alongside the second inputbut compared with the first and second inputs to determine the actualloaded volume and weight of the material added since the first input.After the material corresponding to the third input has been dischargedfrom the loading container, a volume of material remaining (e.g.,carryback material) in the transport vehicle 10 may be determined basedon a fourth input (e.g., from the payload measuring unit) and further inview of the previously determined material density.

In various embodiments, different data processing steps as disclosedherein may be performed in any of various possible stations. Forexample, the controller 212 for the transport vehicle 10 may beconfigured to receive data from the image data source 104 of the workmachine 20 and perform data processing and volume estimation steps basedon supplemental data from the image data source 204 of the transportvehicle 10. As another example, the respective controllers 112, 212 mayindividually perform image data processing steps to calculate/estimatevolumes of the loaded material and the carryback material, respectively,wherein the volume data may be transmitted to a destination includingeither of the controllers 112, 212, an associated user interface, or athird-party device/system.

In an embodiment, a data structure such as for example a customizeddatabase may be developed and stored in association with for examplesuch a third-party system, which is configured to receive scan dataand/or volume data from either or both of the work machine 20 and thetransport vehicle 10 (step 380). The data structure may be populatedwith such data and/or calculations based thereon and/or derivativesthereof to provide a total volume of material removed from a siteassociated with the work machine 20, a total volume of material removedfrom a site associated with the dumping state of the transport vehicle10, or other aggregated values for example associated with a pluralityof work machines 20 and/or transport vehicles 10 in a collective worksite. Data received at a third-party system such as for example acentral server, mobile user device, or the like may further includeidentifiers associated with the respective site, the transmitting workmachine 20 or transport vehicle 10, the user, the time/date, and thelike as part of a data string for appropriately populating the datastructure or feeding into a program engine for generating the dataentering the data structure.

In view of the previous steps and variations thereof, the method 300 mayfurther include a step 390 for displaying relevant information to usersand/or selectively executing control functions based thereon. Forexample, an operator of the transport vehicle 10 may be informed inreal-time of a volume of material remaining in the loading container 14after dumping, or a volume of material currently loaded in the loadingcontainer 14. An automated control function may generate an alert when adetermined volume of material in the loading container 14 during aloading work state exceeds a threshold value, or when a remaining volumeof material in the loading container 14 at the end of a dumping workstate exceeds a threshold value. In an embodiment, an automated controlfunction may repeat one or more aspects of a dumping work state if theremaining volume of material in the loading container 14 at the end of adumping work state exceeds the threshold value.

In view of the above-referenced embodiments and equivalents thereof asmay be appreciated by one of skill in the art, a more accurate andtimely estimation of material volume at each work stage leads to moreaccurate productivity and efficiency calculations.

As used herein, the phrase “one or more of,” when used with a list ofitems, means that different combinations of one or more of the items maybe used and only one of each item in the list may be needed. Forexample, “one or more of” item A, item B, and item C may include, forexample, without limitation, item A or item A and item B. This examplealso may include item A, item B, and item C, or item B and item C.

One of skill in the art may appreciate that when an element herein isreferred to as being “coupled” to another element, it can be directlyconnected to the other element or intervening elements may be present.

Thus, it is seen that the apparatus and methods of the presentdisclosure readily achieve the ends and advantages mentioned as well asthose inherent therein. While certain preferred embodiments of thedisclosure have been illustrated and described for present purposes,numerous changes in the arrangement and construction of parts and stepsmay be made by those skilled in the art, which changes are encompassedwithin the scope and spirit of the present disclosure as defined by theappended claims. Each disclosed feature or embodiment may be combinedwith any of the other disclosed features or embodiments.

What is claimed is:
 1. A method for real-time deduction of materialcarryback in a loading container of a transport vehicle, wherein thematerial is loaded in the loading container by a work machine at a firstsite and dumped from the loading container by the transport vehicle at asecond site, the method comprising: providing, via a first sensorassociated with one of the work machine or the transport vehicle, firstdata corresponding to a volume of material loaded in the loadingcontainer in a first work state; providing, via a second sensorassociated with the other of the work machine or the transport vehicle,second data corresponding to a volume of material loaded in the loadingcontainer in a second work state; and generating an output signalcorresponding to a calculated total volume of material associated with awork cycle, said total volume based at least in part on the providedfirst data and the provided second data.
 2. The method of claim 1,wherein the generated output signal is provided to populate a datastructure with the calculated total volume of material in associationwith at least one of the first site and the second site.
 3. The methodof claim 1, comprising: determining a first volume based at least inpart on the provided first data and information regarding one or moredimensions of the loading container; determining a second volume basedat least in part on the provided second data and the informationregarding one or more dimensions of the loading container; andcalculating the total volume of material associated with the work cyclebased on a difference between the determined first and second volumes.4. The method of claim 3, wherein: the information regarding one or moredimensions of the loading container is stored in association with thetransport vehicle, the first sensor is associated with the work machineand the first data is transmitted from the work machine to the transportvehicle, and the first volume is calculated based on the transmittedfirst data and the stored information regarding one or more dimensionsof the loading container.
 5. The method of claim 3, wherein: the firstsensor comprises a first image data source configured to generatesignals corresponding to a first profile of material loaded in theloading container in the first work state; the second sensor comprises asecond image data source configured to generate signals corresponding toa second profile of material loaded in the loading container in thesecond work state; and the total volume is calculated based at least inpart on a determined first profile and a determined second profile ofloaded material.
 6. The method of claim 5, wherein the informationregarding one or more dimensions of the loading container is obtainedvia scanned images from the first image data source and/or the secondimage data source.
 7. The method of claim 5, wherein the informationregarding one or more dimensions of the loading container is retrievedfrom data storage based upon scanned images comprising an identifierassociated with the transport vehicle.
 8. The method of claim 5, whereinthe information regarding one or more dimensions of the loadingcontainer is retrieved from data storage based upon communicationsbetween the work machine and the transport vehicle and comprising anidentifier associated with the transport vehicle.
 9. The method of claim3, wherein: the first sensor comprises an image data source associatedwith the work machine and configured to generate signals correspondingto a profile of material loaded in the loading container in the firstwork state; and the second sensor comprises a payload measuring unitassociated with the transport vehicle.
 10. The method of claim 9,further comprising: determining a material density of material loaded inthe transport vehicle based on input from the first sensor in the firstwork state and on input from the payload measuring unit in the firstwork state.
 11. The method of claim 10, further comprising: determininga volume of material remaining in the transport vehicle in the secondwork state based on input from the payload measuring unit in the secondwork state and further in view of the determined material density. 12.The method of claim 11, wherein the information regarding one or moredimensions of the loading container is obtained via scanned images fromthe image data source.
 13. The method of claim 11, wherein theinformation regarding one or more dimensions of the loading container isretrieved from data storage based upon scanned images comprising anidentifier associated with the transport vehicle.
 14. The method ofclaim 11, wherein the information regarding one or more dimensions ofthe loading container is retrieved from data storage based uponcommunications between the work machine and the transport vehicle andcomprising an identifier associated with the transport vehicle.
 15. Asystem for real-time deduction of material carryback in a loadingcontainer of a transport vehicle, wherein the material is loaded in theloading container by a work machine at a first site and dumped from theloading container by the transport vehicle at a second site, the systemcomprising: a first sensor associated with one of the work machine orthe transport vehicle and configured to provide first data correspondingto a volume of material loaded in the loading container in a first workstate; a second sensor associated with the other of the work machine orthe transport vehicle and configured to provide second datacorresponding to a volume of material loaded in the loading container ina second work state; and a computing device comprising acomputer-readable medium residing on one of the work machine or thetransport vehicle and having program instructions residing thereon, saidprogram instructions executable by a processor to generate an outputsignal corresponding to a calculated total volume of material associatedwith a work cycle, said total volume based at least in part on theprovided first data and the provided second data.
 16. The system ofclaim 15, wherein the computing device is configured to: determine afirst volume based at least in part on the provided first data andinformation regarding one or more dimensions of the loading container;determine a second volume based at least in part on the provided seconddata and the information regarding one or more dimensions of the loadingcontainer; and calculate the total volume of material associated withthe work cycle based on a difference between the determined first andsecond volumes.
 17. The system of claim 15, wherein: the first sensorcomprises a first image data source configured to generate signalscorresponding to a first profile of material loaded in the loadingcontainer in the first work state; the second sensor comprises a secondimage data source configured to generate signals corresponding to asecond profile of material loaded in the loading container in the secondwork state; and the total volume is calculated based at least in part ona determined first profile and a determined second profile of loadedmaterial.
 18. The system of claim 17, wherein information regarding oneor more dimensions of the loading container is obtained via scannedimages from the first image data source and/or the second image datasource.
 19. The system of claim 17, wherein the information regardingone or more dimensions of the loading container is retrieved from datastorage based upon scanned images comprising an identifier associatedwith the transport vehicle and/or based upon communications between thework machine and the transport vehicle and comprising an identifierassociated with the transport vehicle.
 20. The system of claim 15,wherein: the first sensor comprises an image data source associated withthe work machine and configured to generate signals corresponding to aprofile of material loaded in the loading container in the first workstate; the second sensor comprises a payload measuring unit associatedwith the transport vehicle; and the computing device is configured to:determine a material density of material loaded in the transport vehiclebased on input from the first sensor in the first work state and oninput from the payload measuring unit in the first work state; anddetermine a volume of material remaining in the transport vehicle in thesecond work state based on input from the payload measuring unit in thesecond work state and further in view of the determined materialdensity.